An automatic calibration and verification device for an electrochemical ozone detector

Abstract

This application discloses an automatic calibration and verification device for an electrochemical ozone detector, comprising: an ozone path for delivering ozone, an air path for delivering air, a mixing chamber for mixing ozone from the ozone path and air from the air path, and a mixing path for delivering the mixed gas in the mixing chamber to the electrochemical ozone detector; the technical solution of this application solves the problems of lack of standard ozone gas, high rate of human error, and low production efficiency.

Description

Technical Field

[0001] This application relates to the field of gas detection technology, and in particular to an automatic calibration and verification device for an electrochemical ozone detector. Background Technology

[0002] With the country's increasing emphasis on safety and the significant effects of ozone in the field of disinfection and sterilization, the huge cost-effectiveness advantage of electrochemical ozone detectors has led to a rapid increase in market demand, and the electrochemical ozone detector industry has also grown rapidly.

[0003] Currently, due to the strong oxidizing properties of ozone gas and its ability to automatically revert to oxygen at room temperature, manufacturers cannot customize and store standard ozone gas for calibrating electrochemical ozone detectors. Furthermore, the output concentration of general ozone generators is too uncertain and has a limited range, making them unsuitable for direct calibration and verification of electrochemical ozone detectors. Additionally, differences in the subjective judgment of concentration data stability and operating techniques among calibration and verification personnel lead to significant inconsistencies, high defect rates in shipments, and low production efficiency during large-scale production. There are even instances of miscalibration and omissions, posing significant safety risks to users. Summary of the Invention

[0004] This application proposes an automatic calibration and verification device for an electrochemical ozone detector, which solves the problems of lack of standard gas for ozone, high rate of human error in operation, and low production efficiency.

[0005] This application provides an automatic calibration and verification device for an electrochemical ozone detector, comprising: an ozone path for delivering ozone, an air path for delivering air, a mixing chamber for mixing ozone from the ozone path and air from the air path, and a mixing path for delivering the mixed gas in the mixing chamber to the electrochemical ozone detector.

[0006] The ozone circuit includes an ozone generator that generates ozone, the output of which is connected to a first electronic flow controller, and the output of the first electronic flow controller is connected to the mixing chamber.

[0007] The air path includes an air pump for collecting air, the output end of which is connected to a second electronic flow controller, and the output end of the second electronic flow controller is connected to the mixing chamber.

[0008] The gas mixing path includes a third three-way pipe connected to the output end of the gas mixing chamber. The first outlet of the third three-way pipe is connected to an analyzer for real-time monitoring and analysis of the concentration of the mixed gas in the gas mixing path. The second outlet of the third three-way pipe is connected to a fourth electronic flow controller. The output end of the fourth electronic flow controller is connected to the electrochemical ozone detector.

[0009] It also includes a control module, to which the first electronic flow controller, the second electronic flow controller, the fourth electronic flow controller, the analyzer, and the electrochemical ozone detector are all connected. The control module is also connected to a pump drive unit for controlling the gas pump.

[0010] In some embodiments, the ozone generator is connected to the first electronic flow controller via a first tee pipe, the inlet of the first tee pipe is connected to the ozone generator, the first outlet of the first tee pipe is connected to a third electronic flow controller, and the second outlet of the first tee pipe is connected to the first electronic flow controller; the third electronic flow controller is connected to the control module.

[0011] In some embodiments, the fourth electronic flow controller is connected to the electrochemical ozone detector via a fourth three-way pipe, the inlet of the fourth three-way pipe is connected to the fourth electronic flow controller, the first outlet of the fourth three-way pipe is connected to a fifth electronic flow controller, and the second outlet of the fourth three-way pipe is connected to the electrochemical ozone detector; the fifth electronic flow controller is connected to the control module.

[0012] In some embodiments, the analyzer is configured as an ultraviolet ozone analyzer.

[0013] In some embodiments, a filter is connected to the ozone generator and the air pump inlet via a second tee pipe between the first electronic flow controller, the second electronic flow controller, and the mixing chamber.

[0014] In some embodiments, the ozone generator and the air inlet of the air pump are each connected to a filter.

[0015] In some embodiments, the mixing chamber is equipped with a fan for thoroughly mixing ozone and air.

[0016] In some embodiments, the control module includes an STM32F407ZET6 MCU unit.

[0017] In some embodiments, the MCU unit is also connected to a wireless communication unit for communicating with the outside, a key recognition unit for key control, a power control unit for converting external 220V voltage, a data storage unit for storing data, a data export unit for exporting data, a PC communication unit for connecting to an external computer, an LCD display unit for displaying data, and an audio-visual prompt unit for signal reminders.

[0018] In some embodiments, the wireless communication unit includes a Bluetooth communication unit, a LoRa communication unit, and a 4G communication unit.

[0019] Compared with existing technologies, the advantages of this application are as follows: The multi-stage three-way pipe and venting structure allows for precise and stable control of the gas flow rate and concentration output from each gas path, thus ensuring the stability of the detector's monitoring data; the addition of a fan in the mixing chamber ensures more thorough gas mixing, while real-time monitoring of the vented gas flow rate guarantees uniform and stable input to the instrument; the use of a high-precision ultraviolet ozone analyzer as a comparison measuring instrument ensures calibration error; real-time storage of historical records and status facilitates after-sales data traceability; real-time wireless data upload enables remote monitoring and operation; the ozone generator output concentration is standardized, eliminating the need to rely on standard gases; and fully automated control and operation ensure consistency, effectively controlling defect rates and production efficiency. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the automatic calibration and verification device of this application;

[0022] Figure 2 This is the schematic diagram of the MCU unit circuit in this application;

[0023] Figure 3 This is the circuit schematic of the wireless communication unit of this application;

[0024] Figure 4 This is the circuit schematic of the key recognition unit in this application;

[0025] Figure 5 This is the circuit schematic of the power control unit of this application;

[0026] Figure 6 This is the schematic diagram of the data storage unit circuit in this application;

[0027] Figure 7 Derive the unit circuit schematic for the data in this application;

[0028] Figure 8 This is the circuit schematic of the PC communication unit in this application;

[0029] Figure 9 This is the circuit schematic of the LCD display unit of this application;

[0030] Figure 10 This is the circuit schematic diagram of the audio-visual prompt unit in this application;

[0031] Figure 11 This is the circuit schematic of the communication unit of the electronic flow controller in this application;

[0032] Figure 12 This is a schematic diagram of the communication unit circuit of the detector in this application;

[0033] Figure 13 For this application Figure 2 Enlarged illustration Figure 1 ;

[0034] Figure 14 For this application Figure 2 Enlarged illustration Figure 2 ;

[0035] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0036] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0037] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used in this application's specification is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0038] This embodiment presents an automatic calibration and verification device for an electrochemical ozone detector, referencing... Figure 1 It includes: an ozone path for delivering ozone, an air path for delivering air, a mixing chamber for mixing ozone from the ozone path and air from the air path, and a mixing path for delivering the mixed gas in the mixing chamber to the electrochemical ozone detector.

[0039] The ozone circuit includes an ozone generator that generates ozone, the output of which is connected to a first electronic flow controller, and the output of the first electronic flow controller is connected to the mixing chamber.

[0040] The air path includes an air pump for collecting air, the output end of which is connected to a second electronic flow controller, and the output end of the second electronic flow controller is connected to the mixing chamber.

[0041] The gas mixing path includes a third three-way pipe connected to the output end of the gas mixing chamber. The first outlet of the third three-way pipe is connected to an analyzer for real-time monitoring and analysis of the concentration of the mixed gas in the gas mixing path. The second outlet of the third three-way pipe is connected to a fourth electronic flow controller. The output end of the fourth electronic flow controller is connected to the electrochemical ozone detector.

[0042] It also includes a control module, to which the first electronic flow controller, the second electronic flow controller, the fourth electronic flow controller, the analyzer, and the electrochemical ozone detector are all connected. The control module is also connected to a pump drive unit for controlling the gas pump.

[0043] Furthermore, the ozone generator is connected to the first electronic flow controller via a first three-way pipe. The inlet of the first three-way pipe is connected to the ozone generator, the first outlet of the first three-way pipe is connected to a third electronic flow controller, and the second outlet of the first three-way pipe is connected to the first electronic flow controller. The third electronic flow controller is connected to the control module.

[0044] Furthermore, the fourth electronic flow controller is connected to the electrochemical ozone detector via a fourth three-way pipe. The inlet of the fourth three-way pipe is connected to the fourth electronic flow controller, the first outlet of the fourth three-way pipe is connected to a fifth electronic flow controller, and the second outlet of the fourth three-way pipe is connected to the electrochemical ozone detector. The fifth electronic flow controller is connected to the control module.

[0045] Specifically, during operation, the ozone generator is turned on, and air is irradiated by ultraviolet lamps in the ozone generator to produce ozone molecules. The gas flow rate is then controlled by the first electronic flow controller and input into the mixing chamber. The air pump is turned on, and the external air flow rate is controlled by the second electronic flow controller and input into the mixing chamber to fully mix with the ozone. It should be noted that a third electronic flow controller is connected between the ozone generator and the first electronic flow controller through a first three-way pipe. This third electronic flow controller is used to vent excess ozone and control the ozone flow rate in the ozone circuit.

[0046] Ozone and air are thoroughly mixed in the mixing chamber to form a reduced-concentration ozone mixture. This mixture is output through a third three-way connector, and its flow rate is controlled by a fourth electronic flow controller before being delivered to an electrochemical ozone detector for calibration and verification. During this process, a third three-way connector is added between the mixing chamber and the fourth electronic flow controller. This connector connects to an analyzer, allowing for real-time monitoring and analysis of the mixed gas concentration within the mixing path. This controls the gas flow rate throughout the entire path, achieving ozone concentration standardization. Similarly, a fourth three-way connector is added between the fourth electronic flow controller and the electrochemical ozone detector. This fourth three-way connector connects to a fifth flow controller, which controls the gas flow rate and vents excess gas.

[0047] Throughout the process, the control module will preset the standard gas concentration value and receive the gas concentration in the pipeline detected in real time by the analyzer and compare it with the standard value to calculate the ratio of ozone to air required for ozone production. This information will then be fed back to the first electronic flow controller, the second electronic flow controller, and the third electronic flow controller to control the input flow rate of ozone and air.

[0048] Specifically, the MCU unit can automatically adjust the ratio of input ozone to airflow based on calibration settings. When the set concentration is high, the third electronic flow controller is turned off, and the first electronic flow controller is fully turned on, allowing all high-concentration ozone gas to enter the downstream end. Simultaneously, the airflow entering the downstream end is controlled by controlling the air pump and the second electronic flow controller. The airflow is adjusted by real-time monitoring and analysis to obtain the set ozone concentration. When the set concentration is low, if fully turning on the air pump and the second electronic flow controller still cannot reduce the downstream concentration to the required level, the air pump and the second electronic flow controller remain fully turned on, while the third electronic flow controller is turned on to expel some of the high-concentration ozone gas first, assisting the first electronic flow controller in reducing the proportion of high-concentration ozone gas entering the downstream end, thereby obtaining sufficient low-concentration ozone gas.

[0049] Furthermore, in this embodiment, the fourth electronic flow controller mainly plays the role of output flow monitoring. After the flow stabilizes, it is the sum of the flow of the first electronic flow controller and the second electronic flow controller. In order to ensure the pressure balance of the mixing chamber, the fourth electronic flow controller is in a fully open state. It only uses the flow values ​​of the first, second and fourth electronic flow controllers to determine whether the gas path is sealed and whether it has reached a stable state.

[0050] Depending on the set ozone concentration, the input high-concentration ozone flow rate (controlled by the first electronic flow controller) and air flow rate (controlled by the second electronic flow controller) vary, and the output mixed gas flow rate (monitored by the fourth electronic flow controller) also varies, generally between 1 and 3 L / min. However, the pump flow rate of a typical pump-type electrochemical ozone detector is between 0.5 and 0.8 L / min. To ensure a stable intake flow rate for the electrochemical ozone detector, excess mixed gas needs to be discharged through the fifth electronic flow controller. When the fifth electronic flow controller is fully open, the amount of gas discharged is entirely determined by the intake flow rate of the electrochemical ozone detector at the other end. The more gas the detector takes in, the less gas is discharged through the fifth electronic flow controller, and vice versa. As long as there is excess gas discharged here (generally considered to be above 0.3 L / min), it can be considered that the electrochemical ozone detector has obtained sufficient gas input.

[0051] Simultaneously, the control module communicates with the electrochemical ozone detector to obtain relevant parameter information. By controlling the electronic flow controller, it ensures the stability of the airflow detected by the electrochemical ozone detector. Specifically, when the detector is a diffusion type, the fifth electronic flow controller is completely closed. The gas flow rate obtained by the electrochemical ozone detector is entirely determined by the total output flow rate through the fourth electronic flow controller (i.e., the sum of the air passing through the second electronic flow controller and the ozone gas passing through the first electronic flow controller, minus the intake flow rate of the standard instrument). The intake flow rate of the standard instrument is a fixed value. By monitoring the flow rate of the fourth electronic flow controller, the sum of the flow rates of the first and second electronic flow controllers is automatically adjusted proportionally to stabilize the flow rate of the flow controller at 0.3 L / min, thus ensuring that the gas flow rate input to the diffusion type detector is 0.3 L / min. (According to metrological standards, the recommended calibration flow rate for diffusion instruments is generally 0.2–0.4 L / min; in this embodiment, the intermediate value of 0.3 L / min is used.) When the detection instrument is a pump-type instrument, the fifth electronic flow controller is fully released, and the flow rate of the fifth electronic flow controller is monitored in real time. When its flow rate is less than 0.2 L / min, the inlet flow rate of the two input terminals (the first electronic flow controller and the second electronic flow controller) is increased synchronously by an equivalent proportion until the flow rate of the fifth electronic flow controller is stable between 0.2 and 0.3 L / min, to ensure that there is enough gas to meet the pumping requirements of the pump-type gas detector.

[0052] After the MCU unit determines that the output flow rate is stable based on data from the fourth and fifth electronic flow controllers, it communicates with the electrochemical ozone detector to obtain the real-time concentration data and analyzes the concentration data and its rise curve. Once the calibration and verification conditions are met, it outputs a calibration command (during calibration) or a verification result (during verification). Upon completion of calibration or verification, it provides an audible and visual prompt and stores a calibration or verification record in the data storage unit. It should be noted that, based on the characteristics of the electrochemical sensor, its response curve is close to a logarithmic curve, with a rapid initial rise followed by a slower rise, even approaching a horizontal straight line. The MCU monitors the real-time concentration and determines the rate of increase per unit time. When the rate of increase is less than 0.2% * real-time value / min, the verification and calibration conditions are considered met.

[0053] Furthermore, the analyzer is configured as an ultraviolet ozone analyzer to improve the accuracy of concentration detection.

[0054] Furthermore, the first electronic flow controller, the second electronic flow controller, and the mixing chamber are connected by a second three-way pipe, so that ozone in the ozone path and air in the air path are transported to the mixing chamber through the second three-way pipe.

[0055] Furthermore, the ozone generator and the air pump are each connected to a filter to filter water vapor and dust in the air. In this embodiment, the filter can be a high-molecular PTFE filter element to improve the filtration effect.

[0056] Furthermore, the mixing chamber is equipped with a fan for thoroughly mixing ozone and air, which allows the ozone and air to be mixed even more thoroughly.

[0057] Further, refer to Figure 2 , Figure 13 , Figure 14 In this embodiment, the control module includes an STM32F407ZET6 MCU unit, which is used for data communication, calculation, analysis, and control of various peripheral devices.

[0058] Furthermore, the MCU unit is also connected to a wireless communication unit for communicating with the outside, a key recognition unit for key control, a power control unit for converting external 220V voltage, a data storage unit for storing data, a data export unit for exporting data, a PC communication unit for connecting to an external computer, an LCD display unit for displaying data, and an audio-visual prompt unit for signal reminders.

[0059] Further, refer to Figure 3The wireless communication unit includes a Bluetooth communication unit, a LoRa communication unit, and a 4G communication unit. Depending on the application scenario, a Bluetooth communication unit, a LoRa communication unit, or a 4G communication unit can be selected. The wireless communication unit is connected via UART and used to communicate with a PC or cloud monitoring platform.

[0060] Further reference Figure 4 The button recognition unit is used to recognize button operations, input data, or commands.

[0061] Further, refer to Figure 5 The power adapter converts AC 220V to DC 24V, and then outputs multiple different power supplies through the power control unit to power the air pump, MCU unit and peripheral electronic devices.

[0062] Further, refer to Figure 6 The storage unit uses a high-capacity SPI FLASH storage chip to store calibration and verification data records;

[0063] Further, refer to Figure 7 The data export unit has a HOST USB function for exporting data to a USB flash drive.

[0064] Further, refer to Figure 8 The PC communication unit communicates with the PC via UART to RS485 converter, and is used to communicate with the PC-side monitoring platform.

[0065] Further, refer to Figure 9 The LCD display unit uses liquid crystal display and driving technology for information viewing and human-machine interface interaction.

[0066] Further, refer to Figure 10 The audio-visual prompt unit is used to provide audio-visual prompts for calibration or verification status.

[0067] refer to Figure 11 The electronic flow controller communication unit is used by the MCU unit to control and communicate with each electronic flow controller via UART-to-RS485 signals.

[0068] refer to Figure 12 The detector communication unit is used for communication and connection between the MCU unit and the detector.

[0069] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. An automatic calibration and verification device for an electrochemical ozone detector, characterized in that, include: The ozone path is used to deliver ozone, the air path is used to deliver air, the mixing chamber is used to mix the ozone in the ozone path and the air in the air path, and the mixing path is used to deliver the mixed gas in the mixing chamber to the electrochemical ozone detector. The ozone circuit includes an ozone generator that generates ozone, the output of which is connected to a first electronic flow controller, and the output of the first electronic flow controller is connected to the mixing chamber. The air path includes an air pump for collecting air, the output end of which is connected to a second electronic flow controller, and the output end of the second electronic flow controller is connected to the mixing chamber. The gas mixing path includes a third three-way pipe connected to the output end of the gas mixing chamber. The first outlet of the third three-way pipe is connected to an analyzer for real-time monitoring and analysis of the concentration of the mixed gas in the gas mixing path. The second outlet of the third three-way pipe is connected to a fourth electronic flow controller. The output end of the fourth electronic flow controller is connected to the electrochemical ozone detector. It also includes a control module, to which the first electronic flow controller, the second electronic flow controller, the fourth electronic flow controller, the analyzer and the electrochemical ozone detector are all connected. The control module is also connected to a pump drive unit for controlling the gas pump. The ozone generator is connected to the first electronic flow controller via a first tee pipe. The inlet of the first tee pipe is connected to the ozone generator, the first outlet of the first tee pipe is connected to a third electronic flow controller, and the second outlet of the first tee pipe is connected to the first electronic flow controller. The third electronic flow controller is connected to the control module. The fourth electronic flow controller is connected to the electrochemical ozone detector via a fourth three-way pipe. The inlet of the fourth three-way pipe is connected to the fourth electronic flow controller, the first outlet of the fourth three-way pipe is connected to a fifth electronic flow controller, and the second outlet of the fourth three-way pipe is connected to the electrochemical ozone detector. The fifth electronic flow controller is connected to the control module. The first electronic flow controller, the second electronic flow controller, and the mixing chamber are connected by a second tee pipe; The ozone generator and the air pump are each connected to a filter at their respective air inlets; The mixing chamber is equipped with a fan for thoroughly mixing ozone and air.

2. The automatic calibration and verification device for an electrochemical ozone detector as described in claim 1, characterized in that, The analyzer is configured as an ultraviolet ozone analyzer.

3. The automatic calibration and verification device for an electrochemical ozone detector as described in claim 1, characterized in that, The control module includes an STM32F407ZET6 MCU unit.

4. The automatic calibration and verification device for an electrochemical ozone detector as described in claim 3, characterized in that, The MCU unit is also connected to a wireless communication unit for external communication, a key recognition unit for key control, a power control unit for converting external 220V voltage, a data storage unit for data storage, a data export unit for data export, a PC communication unit for connecting to an external computer, an LCD display unit for data display, and an audio-visual prompt unit for signal alerts.

5. The automatic calibration and verification device for an electrochemical ozone detector as described in claim 4, characterized in that, The wireless communication unit includes a Bluetooth communication unit, a LoRa communication unit, and a 4G communication unit.

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